Interlocking stacking container

ABSTRACT

A container configured to stack and interlock with similar adjacent containers. The container includes a body defining a material receiving chamber, a dispenser opening, and a movable coupler.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/255,936, filed Oct. 29, 2009, the disclosure of which is expressly incorporated herein by reference.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates to a container that is configured to stack and also interlock with other containers so that it is self supporting and will reduce or eliminate the need for secondary packaging. The container illustratively may be comprised of a body that is configured to hold a volume of material, a cover or lid, and a movable coupler that is configured to serve as an interlocking member with other containers.

The device of the present disclosure illustratively acts not only as a container, but is also configured to palletize in a manner where little or no additional packing is needed. More particularly, each container is configured to stack and interlock with other containers positioned above and adjacent to it, thus reducing or eliminating the need for additional materials such as slip sheets, trays and corrugated cartons. Because of its shape, the container will also allow for improved utilization of a pallet area thus increasing the volume of product that will fit onto a pallet.

The movable coupler may alternatively function as an interlocking member and a carrying device for the container. It can also act as a member to ease the act of pouring product from the container. Illustratively, the container includes four side walls defining a square cross-section, each side wall having a substantially flat and large surface area, thereby providing room for product descriptive labeling.

An additional method of interlocking may be accomplished by building an interlocking member into the body of the container itself. Because most commercial containers are made from flexible plastic, the mechanical interlock could be made strong enough to keep the containers interlocked but also flexible enough so a consumer could separate them.

According to an illustrative embodiment of the present disclosure, a container includes a body having a base, a top wall, and at least one side wall defining a material receiving chamber. A dispenser opening is formed in the body and is in communication with the material receiving chamber. A coupler is supported by the body for movement relative thereto. A retaining boss defining a receiving channel is formed in the body. The coupler is configured to be received within the receiving channel of a second container such that the coupler of the container cooperates with the retaining boss of the second container to restrain relative movement of the second container.

According to another illustrative embodiment of the present disclosure, a container includes a body having a base, a top wall, and at least one side wall defining a material receiving chamber. A dispenser opening is formed in the body and is in communication with the material receiving chamber. A bail is pivotably coupled to the body between an upwardly extending carrying mode of operation and a horizontally extending coupling mode of operation. A retaining boss defining a receiving channel is formed in the bail. The bail is configured to be received within the receiving channel of a second container when the bail is in the coupling mode of operation.

According to a further illustrative embodiment of the present disclosure, a stacking container system includes a first container including a base, a top wall, a side wall coupled between the base and the top wall, and a first coupler configured to extend laterally outwardly relative to the top wall. A second container including a base, a top wall, a side wall coupled between the base and the top wall, and a first coupler configured to extend laterally outwardly relative to the top wall, the side wall of the first container being juxtaposed with the side wall of the second container. A third container includes a base, a top wall, a side wall coupled between the base and the top wall, and a first coupler configured to extend laterally outwardly relative to the top wall, the top wall of the first container being juxtaposed with the base of the third container. A fourth container including a base, a top wall, a side wall coupled between the base and the top wall, and a first coupler configured to extend laterally outwardly relative to the top wall, the top wall of the second container being juxtaposed with the base of the fourth container, the side wall of the third container being juxtaposed with the side wall of the fourth container, and the first coupler of the first container coupled to the base of the fourth container.

Additional features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of the illustrative embodiment exemplifying the best mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description of the drawings particularly refers to the accompanying figures in which:

FIG. 1 is a perspective view of an illustrative container of the present disclosure with the coupler in a coupling or rest position;

FIG. 2 is a front view of the container of FIG. 1;

FIG. 3 is a rear view of the container of FIG. 1;

FIG. 4 is a right side view of the container of FIG. 1, showing the coupler in solid line in the coupling or rest position, and in hidden line in a carrying or use position;

FIG. 5 is a left side view of the container of FIG. 1;

FIG. 6 is a top view of the container of FIG. 1;

FIG. 7 is a bottom view of the container of FIG. 1;

FIG. 8 is a perspective view of multiple containers of the type shown in FIG. 1 in a stacking arrangement;

FIG. 9 is a cross-sectional view through the center of the stacked containers of FIG. 8;

FIG. 9A is a detail view of FIG. 9;

FIG. 10 is a perspective view of a plurality of containers of the type shown in FIG. 1 in a stacking arrangement on a pallet;

FIG. 11 is a partial perspective view of the plurality of containers of FIG. 10;

FIG. 12 is a bottom view of multiple containers which illustrates receiving channels in which the coupler of adjacent container(s) rests to provide an interlock between the containers;

FIG. 13 is perspective view of additional interlocking containers wherein the couplers are formed as part of the container bodies; and

FIG. 14 is perspective view of additional interlocking containers having couplers formed as part of the container bodies.

DETAILED DESCRIPTION OF THE DRAWINGS

The embodiments of the invention described herein are not intended to be exhaustive or to limit the invention to precise forms disclosed. Rather, the embodiments selected for description have been chosen to enable one skilled in the art to practice the invention.

Referring initially to FIGS. 1-7, an illustrative container 10 is shown as including a body 12 defining a material receiving chamber 14 (FIG. 9). A wide variety of substances may be stored in the material receiving chamber 14, including fluids, granular materials, etc. Illustratively, the body 10 may be formed of a thermoplastic through a conventional blow molding operation. Other materials and manufacturing processes may be substituted for use with the present disclosure. The body 12 is shown as including a base 16, a top wall 18, and a plurality of side walls 20, 22 connecting the base 16 and the top wall 18.

In the illustrative embodiment of FIGS. 6 and 7, a first pair of parallel sidewalls 20 a, 20 b are disposed perpendicular to a second pair of parallel sidewalls 22 a, 22 b, thereby defining a rectangular cross-section. In one illustrative embodiment, the first pair of sidewalls 20 a, 20 b and the second pair of sidewalls 22 a, 22 b are of substantially equal length, thereby defining a square cross-section. The symmetrical arrangement of the body 12 about longitudinal (x) axis 24 and/or lateral (y) axis 25 (FIG. 6) facilitates the placement, stacking, and interlocking of adjacent containers 10. The side walls 20, 22 each have a large substantially planar surface area 26 providing space to label the product. While the relative dimensions may vary based upon user preference, in one illustrative embodiment each container 10 has a width of approximately 6.5 inches, a depth of approximately 6.5 inches, and a height of approximately 4.7 inches.

A dispenser opening 28 is formed within the body 12 and is in communication with the material receiving chamber 14 (FIG. 9). The dispenser opening 28 is defined by a dispenser wall 30 extending upwardly from the top wall 18 of the body 12. In one illustrative embodiment, the dispenser wall 30 is cylindrical and includes a plurality of external threads 32 configured to threadably couple with internal threads 34 of a removable cover or lid 36 (FIG. 9A). The cover 36, which may be molded from a thermoplastic, is configured to cover the dispenser opening 28 to prevent the unintended discharge of material from the material receiving chamber 14. A gasket, such as an o-ring, may be provided between the dispenser wall 30 and the cover 36 to facilitate sealing therebetween, particularly if fluids are stored in the material receiving chamber 14. In other illustrative embodiments, the dispenser wall 30 and the cover 36 may be of different shapes and include various coupling means, such as bayonet couplers, resilient catches, or snap rings.

With reference to FIGS. 2-6 and 8-9A, a plurality of retaining bosses 40 are formed in the base 16 of body 12. More particularly, a separate retaining boss 40 a, 40 b, 40 c, 40 d is illustratively associated with each side wall 20 a, 22 a, 20 b, 22 b, respectively, thereby enhancing flexibility in coupling with adjacent containers 10. Each retaining boss 40 a, 40 b, 40 c, 40 d defines a receiving channel 42 a, 42 b, 42 c, 42 d in the base 16 in a direction inwardly from the associated side wall 20 a, 22 a, 20 b, 22 b toward a center of the body 12. In the illustrative embodiment, each receiving channel 42 is arcuate, such as semicircular, in shape. However, other configurations may be substituted therefore. Further, while the retaining bosses 40 and the associated receiving channels 42 are shown as being supported by the base 16, it should be appreciated that these elements may also be supported by other portions of the body 12, such as the top wall 18.

A coupler 44 is illustratively supported by the body 12 for pivoting movement relative thereto. More particularly, the coupler 44 may comprise a bail 46, such as a strap formed into a partial loop, having opposing ends pivotably coupled at pivot points 50 a, 50 b above the top wall 18. As further detailed herein, the coupler 44 has a carrying or use mode of operation where the bail 46 extends substantially vertically or upwardly from the top wall 18, and a coupling or rest mode of operation where the bail 46 extends substantially horizontal or parallel to the top wall 18.

The coupler 44 may be formed of any material having sufficient strength to support the weight of material in the container 10 during the carrying mode and to provide a sufficient container interlock during the coupling mode, and of sufficient flexibility to facilitate release of the container interlock by a user. Illustratively, the bail 46 may be formed of a conventional polymer and/or elastomeric material.

With reference to FIGS. 8 and 9, the material receiving chambers 14 and the receiving channels 42 of stacked containers 10 a, 10 b, 10 c, 10 d are illustrated. As further detailed herein, the receiving channels 42 of each container 10 (e.g., container 10 d in FIG. 9) permit the nesting therein of coupler 44 of another adjacent container 10 (e.g., container 10 a in FIG. 9). FIG. 9 also shows a recess 56 formed in the base 16 of each container 10 to thus allow the dispenser wall 30 and cooperating cover 36 to rest into the container 10 above it, which also stabilizes the containers 10 relative to each other (e.g. containers 10 a, 10 c and containers 10 b, 10 d in FIG. 9). As such, the dispenser wall 30 and the cover 36 define a second coupler for each container 10 to work in cooperation with the coupler 44.

In the stacked arrangement of containers 10 a, 10 b, 10 c, 10 d shown in FIGS. 8 and 9, second container 10 b is positioned horizontally adjacent to first container 10 a, third container 10 c is positioned above first container 10 a, and fourth container 10 d is positioned above second container 10 b and horizontally adjacent to third container 10 c. The side wall 22 a of first container 10 a is juxtaposed with the side wall 22 b of the second container 10 b. The third container 10 c is positioned directly above first container 10 a, and is configured to rest on an upper surface of cover 36 of container 10 a and will also rest on upper surface of top wall 18 of container 10 a, thereby distributing the load of the second container 10 b. The fourth container 10 d is positioned directly above second container 10 b to rest on cover 36 and top wall 18 of second container 10 b. Further, the side wall 22 a of third container 10 c is juxtaposed with side wall 22 b of fourth container 10 d.

The coupler 44 of first container 10 a is positioned in an interlocking position (i.e. coupling mode) by nesting in receiving channel 42 of fourth container 10 d, where it couples adjacent containers 10 a and 10 d. Similarly, second coupler defined by dispenser wall 30 and cover 36 of first container 10 a is positioned in an interlocking position by nesting in recess 56 of third container 10 c, where it couples adjacent containers 10 a and 10 c. As shown in FIGS. 7 and 12, channels 57 are provided in the base 16 and link the various receiving channels 42. Channels 57 are clearance channels for the coupler 44 of a container 10 that sits directly below the container 10 in a stacked arrangement (e.g., clearance channels 57 of containers 10 c, 10 d receive the bails 46 of containers 10 a, 10 b, respectively).

With reference to FIG. 9A, a detailed view of FIG. 9 shows the interaction of the bail 46 and receiving channel 42 of container 10 d. Also shown are additional details of the interaction of the dispenser wall 30 and cover 36 of container 10 b and the recess 56 of container 10 d.

FIG. 10 shows a stacked assembly 60 of containers 10 supported on a pallet 62, while FIG. 11 details a corner portion 63 of the stacked assembly 60. The stacked assembly 60 illustratively includes a plurality of first rows 64 of containers 10 and a plurality of second rows 66 of containers 10, the first rows 64 extending perpendicular to the second rows 66. The rows 64 and 66 are stacked in a plurality of planes 68 of containers 10. In the illustrative embodiment of FIG. 10, the first rows 64 have a length of approximately 32.5 inches, the second rows 66 have a length of approximately 39 inches, and the planes 68 define a height of stacked assembly 60 of approximately 51.7 inches.

With reference to FIGS. 7 and 12, the receiving channels 42 a, 42 b, 42 c, 42 d of each container 10 are in four locations and offset 90 degrees from each other, thereby allowing the container 10 to be interlocked with adjacent containers 10 in any one of four orientations because the container footprint is square. This allows the couplers 44 to face inward of the outside rows 64 of stacked assembly 60 so that no coupler 44 hangs over the row 64 and outside of the assembly 60 (FIGS. 10 and 11). This also allows for either specific or random placement/orientation of the containers 10 depending upon preference and the need for interlocking in multiple directions to assist in stabilizing the stacked assembly 60 on pallet 62. As detailed above, clearance channels 57 receive the couplers 44 of a container 10 directly therebelow.

With reference to FIG. 13, another method of interlocking includes containers 100, each container 100 including couplers 102 and receiving channels 104. The couplers 102 are illustratively tabs configured to be received within channels 104. The couplers 102 and channels 104 may be molded as part of the body 106 of the each container 100.

With reference to FIG. 14, another method of interlocking includes containers 200, each container 200 including couplers 202 configured to nest in recesses 204. Stabilizing members 206 may extend from an upper end of the body 208 of each container 200 and are configured to be received within recesses 210 formed in a lower end of the body 208, thereby creating another stabilizing member.

Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the spirit and scope of the invention as described and defined in the following claims. 

1. A container comprising: a body including a base, a top wall, and at least one sidewall defining a material receiving chamber; a dispenser opening formed in the body and in communication with the material receiving chamber; a coupler supported by the body for movement relative thereto; a retaining boss defining a receiving channel in the body; and wherein the coupler is configured to be received within the receiving channel of a second container such that the coupler of the container cooperates with the retaining boss of the second container to restrain relative movement of the second container.
 2. The container of claim 1, wherein the dispenser opening is defined by a dispenser wall extending upwardly from the top wall of the body, and a cover is releasably coupled to the dispenser wall.
 3. The container of claim 2, wherein the dispenser wall is cylindrical and includes a plurality of external threads, and the cover includes a lid having a plurality of internal threads engaging the external threads of the dispenser wall.
 4. The container of claim 2, wherein: the base includes a recess; and the dispenser wall and the cover are configured to be received within the recess of the base of a third container supported by the top wall of the container.
 5. The container of claim 1, wherein the at least one sidewall includes a first pair of parallel sidewalls and a second pair of parallel sidewalls thereby defining a rectangular cross-section.
 6. The container of claim 5, wherein the first pair of sidewalls and the second pair of sidewalls are of substantially equal length thereby defining a square cross-section.
 7. The container of claim 1, wherein the coupler comprises a bail pivotably supported by the body.
 8. The container of claim 7, wherein the bail includes a first end pivotably coupled to the top wall proximate a first side of the dispenser opening and a second end pivotably coupled to the top wall proximate an opposing second side of the dispenser opening, the bail defining a handle when in a carrying mode of operation and the bail restraining movement of the second container in a plane parallel to the top wall of the container when in a coupling mode of operation.
 9. A container comprising: a body including a base, a top wall, and at least one sidewall defining a material receiving chamber; a dispenser opening formed in the body and in communication with the material receiving chamber; a bail pivotably coupled to the body between a upwardly extending carrying mode of operation and a horizontally extending coupling mode of operation; a retaining boss defining a receiving channel in the body; and wherein the bail is configured to be received within the receiving channel of a second container when the bail is in the coupling mode of operation.
 10. The container of claim 9, wherein the bail in the coupling mode of operation cooperates with the retaining boss of the second container to restrain movement of the second container in a plane parallel to the top wall of the container.
 11. The container of claim 9, wherein the dispenser opening is defined by a dispenser wall extending upwardly from the top wall of the body.
 12. The container of claim 11, further comprising a cover releasably coupled to the dispenser wall.
 13. The container of claim 12, wherein the dispenser wall is cylindrical and includes a plurality of external threads, and the cover includes a lid having a plurality of internal threads engaging the external threads of the dispenser wall.
 14. The container of claim 12, wherein: the base includes a recess; and the dispenser wall and the cover are configured to be received within the recess of a third container supported by the top wall of the container.
 15. The container of claim 9, wherein the at least one sidewall includes a first pair of parallel sidewalls and a second pair of parallel sidewalls thereby defining a rectangular cross-section.
 16. The container of claim 9, wherein the bail includes a first end pivotably coupled to the top wall proximate a first side of the dispenser opening and a second end pivotably coupled to the top wall proximate an opposing second side of the dispenser opening, the bail defining a handle when in a carrying mode of operation.
 17. A stacking container system comprising: a first container including a base, a top wall, a sidewall coupled between the base and the top wall, and a first coupler configured to extend laterally outwardly relative to the top wall; a second container including a base, a top wall, a sidewall coupled between the base and the top wall, and a first coupler configured to extend laterally outwardly relative to the top wall, the sidewall of the first container being juxtaposed with the sidewall of the second container; a third container including a base, a top wall, a sidewall coupled between the base and the top wall, and a first coupler configured to extend laterally outwardly relative to the top wall, the top wall of the first container being juxtaposed with the base of the third container; and a fourth container including a base, a top wall, a sidewall coupled between the base and the top wall, and a first coupler configured to extend laterally outwardly relative to the top wall, the top wall of the second container being juxtaposed with the base of the fourth container, the sidewall of the third container being juxtaposed with the sidewall of the fourth container, and the first coupler of the first container coupled to the base of the fourth container.
 18. The stacking container system of claim 17, wherein the first container further comprises a second coupler, the second coupler of the first container coupled to the base of the third container.
 19. The stacking container system of claim 18, wherein the first coupler of the first container comprises a bail supported for pivoting movement relative to the top wall, and the second coupler of the first container comprises a dispenser wall surrounding a dispenser opening and extending upwardly from the top wall.
 20. The stacking container system of claim 18, wherein the first coupler of the first container comprises a bail supported for pivoting movement, and a retaining channel is formed in the base of the fourth container, the bail of the first container being received within the receiving channel of the fourth container and secured within the receiving channel by the top wall of the second container. 